Method of assembling, dissembling and shipping a ready to assemble recliner

ABSTRACT

A recliner or other article of sitting furniture having an assembled configuration and a disassembled configuration, said disassembled configuration including storage cavities in at least one of an arm portion, a seat cavity, a back portion, and combinations thereof, where any of said cavities are used to optimize storage volume in said disassembled configuration and a method of shipping a recliner in said disassembled configuration.

INDEX TO RELATED APPLICATIONS

This application is a non-provisional of, and claims benefit to U.S. Provisional Patent Application Ser. No. 61/758,263 filed Jan. 29, 2013 the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The furniture industry has long felt the need to optimize volume in shipping containers. However, certain configurations of furniture do not lend themselves well to optimization of space. The present invention has addressed this need for optimization when shipping recliners by providing a recliner having configured storage cavities whereby said storage cavities can impart a disassembled configuration of a substantially rectangle or solid. The rectangle or solid is useful in optimizing shipping volume.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is a recliner having an assembled configuration and a disassembled configuration, said disassembled configuration including storage cavities in at least one of an arm portion, a seat box, a back portion, and combinations thereof, where any of said cavities are used to optimize storage volume in said disassembled configuration.

Although the particular drawings herein are directed to a recliner chair, the present invention contemplates use with sofas, loveseats, and other articles of furniture.

In one embodiment, the arm portion has a cavity that is constructed and arranged to store any of cushions, fiber, recliner scissor mechanisms, base frame, or combinations thereof.

In one embodiment, the recliner seat box has a cavity that is constructed and arranged to store any of cushions, fiber, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.

In one embodiment, the recliner back frame has a cavity that is constructed and arranged to store any of cushions, fiber, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.

The present invention includes a method of shipping a recliner comprising: providing a recliner according to claim 1; forming said recliner into the disassembled configuration; optimizing said storage cavities whereby said recliner in the disassembled configuration is optimized into the shape of a rectangular solid; packaging said rectangular solid; and shipping said rectangular solid.

Because of the novel nesting unassembled configuration the method including shipping a plurality of said solids, whereby said shipping of plurality includes an increase of 100 to 300% more than shipping of conventional recliners.

In one embodiment the invention includes an article of sitting furniture having an assembled configuration and a disassembled configuration, said disassembled configuration including one or more storage cavities in at least one of an arm portion, a seat box, a back portion, or combinations thereof, wherein any of said one or more storage cavities are used to optimize storage volume in said disassembled configuration.

In one embodiment, the article of furniture arm portion has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, or combinations thereof.

In one embodiment, the article of furniture seat box has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.

In one embodiment, the article of furniture back frame has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.

In one embodiment, the article of furniture is a recliner chair, recliner rocker, sofa, or loveseat.

In one embodiment, the article of furniture article is fully upholstered in each configuration.

The invention also includes a method of shipping a sitting article of furniture comprising: providing a sitting article of furniture according to the present invention; forming said a sitting article of furniture into the disassembled configuration; optimizing said storage cavities whereby said a sitting article of furniture in the disassembled configuration is optimized into the shape of a rectangular solid; packaging said rectangular solid; and shipping said rectangular solid.

The method includes shipping a plurality of said packaged furniture solids, whereby said shipping of plurality includes an increase of 100 to 300% more than shipping of conventional a sitting article of furniture.

The method article is a recliner chair, recliner rocker, sofa, loveseat, or combinations thereof.

In one embodiment, the furtniture article is fully upholstered in each configuration.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is an exploded view of the recliner assembly component parts.

FIG. 2 is one configuration of the scissors and furniture arm ready for packing as per FIG. 6A.

FIG. 2A is a configuration demonstrating component parts in a nesting relationship.

FIG. 3 is a configuration with a scissors assembly nested inside of a single arm cavity.

FIG. 4 is a configuration with a cushion and arm ready for packaging as per FIG. 6B.

FIG. 5 is a cushion nested within a single arm cavity.

FIG. 6A is a packing arrangement as per FIG. 2.

FIG. 6B is a packing arrangement as per FIG. 4

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention has provided for a novel configuration whereby a ready to assemble recliner detaches into discrete parts in order to maximize a shape and configuration for shipping.

In unassembled configuration is contemplated that the component parts fit into a substantially rectangular configuration such as a rectangular box 30. Various combinations are contemplated with component parts nested within cavities without limitation including component parts nested with in either or both arm components, a back component, and a seat box frame. Thus, for example, the scissor assembly is configured such that it is constructed and arranged to nest selectively in any one of the seatback, the arms, the back portion, or the frame.

In one embodiment, the assembled and disassembled configurations are achieved without hand tools, screws, nuts, bolts, and the like. Assembly 10 includes an arm portion 14 formed with a hollow cavity 30 therein. Hollow cavity 30 is constructed and arranged to contain component parts of the recliner when the recliner is in a disassembled configuration for shipping. Component parts can include any of recliner mechanism 16, recliner base 20, mechanism case, back cushions 26, seat cushions 28, pillows, combinations thereof and the like, as generally understood.

As generally understood, arm portion 14 has formed therein arm cavity 30. Arm cavity 30 is constructed and arranged complementary with the construction and arrangement of component parts in a ready to a symbol recliner. In one embodiment, as shown in FIGS. 2, 3, 4, and 5, scissor recliner mechanism 30 having a generally planar configuration is constructed and arranged with a compatible storage cavity within a recliner arm portion 20. As demonstrated by subsequent sequential FIGS. 6A and 6B, recliner arm cavity 30 receives scissor mechanism 16, which in said unassembled configuration, nests within cavity 30 of arm

Back portion 12 is configured with a cavity region such that component parts nest therein. Although he figures are demonstrative, they are not exhaustive as to parts configured to nest in back portion 12. Components including any combination of back cushion 26, seat cushion 28, arm 14, and seat base 22 are all contemplated as being configured to nest in the cavity of back portion 12.

Seat base 22 is similarly configured and has a cavity for nesting any of arm 14, scissor 16, back cushion 26, seat cushion 28, in any combination.

Regarding the cushions, it is contemplated that any configuration of cushion, including, but not limited to, foam, fiber, cushions with internal springs and/or spring-like structures, fabric, combinations thereof and the like are nested according to the current invention. The cushion components can be nested as desired in a compressed packaging or an uncompressed form.

As is further understood, component parts of a ready to assemble recliner will have an assembled configuration as is known in the art whereby a usable recliner is produced, and a disassembled configuration whereby said disassembled configuration is constructed and arranged to maximize the volume required when shipping a recliner.

In said disassembled configuration, as is known in the art, it is difficult to ship articles such as recliners because there is a void volume in the shipping container. The void volume refers to volume that is not used and is still occupying volume in a shipping container. The present invention has provided a configuration whereby any one or all of arm portions, cavity underneath the seats, and back portions, each contain internal cavities in order to optimize storage of said disassembled configuration. The disassembled configuration of the present invention has discovered and increased efficiency of 100 to 400% in relation to shipping conventional recliners.

While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. 

I claim:
 1. An article of sitting furniture having an assembled configuration and a disassembled configuration, said disassembled configuration including one or more storage cavities in at least one of an arm portion, a seat box, a back portion, or combinations thereof, wherein any of said one or more storage cavities are used to optimize storage volume in said disassembled configuration.
 2. The article of furniture of claim 1 wherein said arm portion has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, or combinations thereof.
 3. The article of furniture of claim 1 wherein said seat box has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.
 4. The article of furniture of claim 1 wherein said back frame has a cavity that is constructed and arranged to store any of cushions, recliner scissor mechanisms, base frame, arm portions, or combinations thereof.
 5. The article of furniture of claim 1, wherein said article is a recliner chair, recliner rocker, sofa, or loveseat.
 6. The article of furniture of claim 1, wherein said article is fully upholstered in each configuration.
 7. A method of shipping a sitting article of furniture comprising: providing a sitting article of furniture according to claim 1; forming said a sitting article of furniture into the disassembled configuration; optimizing said storage cavities whereby said a sitting article of furniture in the disassembled configuration is optimized into the shape of a rectangular solid; packaging said rectangular solid; and shipping said rectangular solid.
 8. The method of claim 7 including shipping a plurality of said solids, whereby said shipping of plurality includes an increase of 100 to 300% more than shipping of conventional a sitting article of furniture.
 9. The method of claim 7, wherein said article is a recliner chair, recliner rocker, sofa, or loveseat.
 10. The method of claim 7, wherein said article is fully upholstered in each configuration. 